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<p>Preface xxiii</p> <p>Acknowledgments xxvii</p> <p>About the Companion Website xxix</p> <p><b>Part I Introduction and Design Considerations</b> 1</p> <p><b>1 Introduction to Design</b> 3</p> <p>1.1 Introduction 6</p> <p>1.2 Phases of Design 8</p> <p>1.3 Basic Mechanical Functions 9</p> <p>1.4 Design Factors 11</p> <p>1.5 Synthesis Approach to Design 12</p> <p>1.6 Product Life Cycle 13</p> <p>1.7 Business Measures 14</p> <p>1.8 Research and Development Process in Product Cycle 15</p> <p>1.9 Teamwork for Product or System Design 16</p> <p>1.10 Design and Development Case Study 16</p> <p>1.11 Units and Fundamentals 16</p> <p>1.12 Summary 26</p> <p><b>2 Design Considerations</b> 31</p> <p>2.1 Mathematical Modeling 34</p> <p>2.2 Calculation Tools 57</p> <p>2.3 Design Procedure 60</p> <p>2.4 Manufacturing Processes 62</p> <p>2.5 Standard Sets and Components 72</p> <p>2.6 Codes and Standards 72</p> <p>2.7 Summary 73</p> <p><b>Part II Knowledge-Based Design</b> 79</p> <p><b>3 Introduction to Computer-Aided Techniques</b> 81</p> <p>3.1 CAD and Geometric Modeling 82</p> <p>3.2 Geometric Construction and FE Analysis 84</p> <p>3.3 CAD/CAM/CAE and Advanced Systems 85</p> <p>3.4 Virtual Reality 87</p> <p>3.5 Summary 89</p> <p><b>4 Computer-Aided Design </b>91</p> <p>4.1 3D Geometric Modeling and Viewing Transformation 95</p> <p>4.2 Parametric Modeling 111</p> <p>4.3 CAD Hardware and Software 135</p> <p>4.4 Rendering and Animation 135</p> <p>4.5 Data Structure 146</p> <p>4.6 Using CAD in 3D Modeling and CAM 149</p> <p>4.7 Summary 149</p> <p><b>5 Optimization </b>155</p> <p>5.1 Introduction 158</p> <p>5.2 Searches in One Direction 167</p> <p>5.3 Multidimensional: Classical Indirect Approach 173</p> <p>5.4 Multidimensional Unconstrained Problem 179</p> <p>5.5 Multidimensional Constrained Problem 200</p> <p>5.6 Applications to Machine Elements and Systems 209</p> <p>5.7 Summary 213</p> <p><b>6 Stresses, Deformations, and Deflections</b> 221</p> <p>6.1 Loads, Shear, Moment, Slope, and Deflection 227</p> <p>6.2 Mathematical Model 253</p> <p>6.3 Simple Stresses, Strains, and Deformations 254</p> <p>6.4 Combined Stresses 264</p> <p>6.5 Curved Beams 279</p> <p>6.6 Strain Energy and Deflection 283</p> <p>6.7 Columns 288</p> <p>6.8 Equivalent Element 296</p> <p>6.9 Thermal Effects 297</p> <p>6.10 Stress Concentration Factors 300</p> <p>6.11 Finite Element Method 302</p> <p>6.12 Computer-Aided Design and Optimization 323</p> <p>6.13 Summary 333</p> <p><b>7 Materials Static and Dynamic Strength</b>3 43</p> <p>7.1 Material Structure and Failure Modes 348</p> <p>7.2 Numbering Systems and Designations 358</p> <p>7.3 Heat Treatment and Alloying Elements 362</p> <p>7.4 Material Propertied and General Applications 366</p> <p>7.5 Particular Materials for Machine Elements 381</p> <p>7.6 Hardness and Strength 383</p> <p>7.7 Failure and Static Failure Theories 385</p> <p>7.8 Fatigue Strength and Factors Affecting Fatigue 397</p> <p>7.9 Fracture Mechanics and Fracture Toughness 413</p> <p>7.10 Computer-Aided Selection and Optimization 419</p> <p>7.10.1 Material Properties: Carbon Steel 419</p> <p>7.11 Summary 428</p> <p><b>8 Introduction to Elements and System Synthesis</b> 439</p> <p>8.1 Introduction 441</p> <p>8.2 Basic and Common Machine Elements 442</p> <p>8.3 Reverse Engineering 469</p> <p>8.4 Sample Applications 470</p> <p>8.5 Computer-Aided Design 476</p> <p>8.6 System Synthesis 479</p> <p>8.7 Computer-Aided Assembly 480</p> <p>8.8 Summary 480</p> <p><b>Part III Detailed Design of Machine Elements</b> 487</p> <p><b>Section A Basic Joints and Machine Elements</b> 489</p> <p><b>9 Screws, Fasteners, and Permanent Joints</b> 491</p> <p>9.1 Standards and Types 494</p> <p>9.2 Stresses in Threads 497</p> <p>9.3 Bolted Connections 498</p> <p>9.4 Bolt Strength in Static and Fatigue 507</p> <p>9.5 Power Screws 511</p> <p>9.6 Permanent Joints 518</p> <p>9.7 Computer-Aided Design and Optimization 527</p> <p>9.8 Summary 532</p> <p><b>10 Springs </b>539</p> <p>10.1 Types of Springs 542</p> <p>10.2 Helical Springs 542</p> <p>10.3 Leaf Springs 567</p> <p>10.4 Belleville Springs 574</p> <p>10.5 Elastomeric and Other Springs 576</p> <p>10.6 Computer-Aided Design and Optimization 576</p> <p>10.7 Summary 579</p> <p><b>11 Rolling Bearings </b>585</p> <p>11.1 Bearing Types and Selection 588</p> <p>11.2 Standard Dimension Series 590</p> <p>11.3 Initial Design and Selection 592</p> <p>11.4 Bearing Load 595</p> <p>11.5 Detailed Design and Selection 601</p> <p>11.6 Speed Limits 609</p> <p>11.7 Lubrication and Friction 609</p> <p>11.8 Mounting and Constructional Details 610</p> <p>11.9 Computer-Aided Design and Optimization 611</p> <p>11.10 Summary 617</p> <p><b>12 Journal Bearings </b>621</p> <p>12.1 Lubricants 624</p> <p>12.2 Hydrodynamic Lubrication 629</p> <p>12.3 Journal Bearing Design Procedure 641</p> <p>12.4 Boundary and Mixed Lubrication 646</p> <p>12.5 Plain Bearing Materials 648</p> <p>12.6 CAD and Optimization 653</p> <p>12.7 Summary 661</p> <p><b>Section B Power Transmitting and Controlling Elements</b> 667</p> <p><b>13 Introduction to Power Transmission and Control</b> 669</p> <p>13.1 Prime Movers and Machines 671</p> <p>13.2 Collinear and Noncollinear Transmission Elements 671</p> <p>13.3 Power Control Elements 675</p> <p>13.4 Computer-Aided Design of a Power Transmission System 676</p> <p>13.5 Summary 681</p> <p><b>14 Spur Gears </b>683</p> <p>14.1 Types and Utility 687</p> <p>14.2 Definitions, Kinematics, and Standards 688</p> <p>14.3 Force Analysis and Power Transmission 699</p> <p>14.4 Design Procedure 701</p> <p>14.5 Critical Speed 732</p> <p>14.6 CAD and Optimization 734</p> <p>14.7 Constructional Details 742</p> <p>14.8 Summary 747</p> <p><b>15 Helical, Bevel, and Worm Gears </b>755</p> <p>15.1 Helical Gears 758</p> <p>15.2 Bevel Gears 776</p> <p>15.3 Worm Gears 781</p> <p>15.4 Gear Failure Regimes and Remedies 787</p> <p>15.5 Computer-Aided Design and Optimization 787</p> <p>15.6 Constructional Details 794</p> <p>15.7 Summary 795</p> <p><b>16 Flexible Elements</b> 801</p> <p>16.1 V-belts 804</p> <p>16.2 Flat Belts 818</p> <p>16.3 Ropes 823</p> <p>16.4 Chains 831</p> <p>16.5 Friction Drives 839</p> <p>16.6 Flexible Shafts 839</p> <p>16.7 Computer-Aided Design and Optimization 840</p> <p>16.8 Summary 849</p> <p><b>17 Shafts </b>857</p> <p>17.1 Types of Shafts and Axles 859</p> <p>17.2 Mathematical Model 860</p> <p>17.3 Initial Design Estimate 865</p> <p>17.4 Detailed Design 867</p> <p>17.5 Design for Rigidity 871</p> <p>17.6 Critical Speed 872</p> <p>17.7 Computer-Aided Design and Optimization 873</p> <p>17.8 Constructional Details 879</p> <p>17.9 Summary 880</p> <p><b>18 Clutches, Brakes, and Flywheels</b> 887</p> <p>18.1 Classifications of Clutches and Brakes 889</p> <p>18.2 Cone Clutches and Brakes 889</p> <p>18.3 Disk Clutches and Brakes 891</p> <p>18.4 Caliper Disk Brakes 898</p> <p>18.5 Energy Dissipation and Temperature Rise 899</p> <p>18.6 Design Process 901</p> <p>18.7 Computer-Aided Design and Optimization 902</p> <p>18.8 Flywheels 904</p> <p>18.9 Constructional Details 907</p> <p>18.10 Summary 908</p> <p>Problems 908</p> <p>References 911</p> <p>Internet Links 912 </p> <p><b>Appendix A Figures and Tables</b> 913</p> <p>A.1 Conversion Between US and SI Units 913</p> <p>A.2 Standard SI Prefixes 914</p> <p>A.3 Preferred Numbers and Sizes 915</p> <p>A.4 Standard Rods, or Bars 916</p> <p>A.5 Standard Joining and Retaining Elements 917</p> <p>A.6 Standard Sealing Elements 920</p> <p>A.7 Material Properties 922</p> <p>A.8 Standard Sections or Profiles and Section Properties 931</p> <p><b>Index</b> 949</p>

<p><b>SAYED M. METWALLI,</b> is Professor Emeritus of Machine Design and past Chair of Mechanical Design and Production Department, Cairo University, Egypt. He received a BS (Mech. Eng.) with honor from Cairo University (1965) and MS and PhD (Mech. Eng.) from State University of New York at Buffalo, USA, (1970) and (1973) respectively. Metwalli has conducted research and taught at North Carolina State University, the University of Central Florida, USA, and Kuwait University, and holds a US patent. His research interests are in design optimization theory, developing algorithms, and CAD/CAM software, with particular emphasis on optimum synthesis of mechanical components and systems including dynamics and controls for multitude of applications. He has conducted sponsored research with DOD/NRL, UNESCO, IBM-UK, NSF, EPA, USAID, and CU and has published more than 150 papers in journals and peer reviewed international conferences. His work with various manufacturers successfully implemented CAD and design optimization in their product design and development. He is an ASME Life Fellow, registered mechanical design consultant, and has been a registered PE in Florida.</p>

<p><b>A guide to the new CAD and optimization tools and skills to generate real design synthesis of machine elements and systems</b><p><i>Machine Design with CAD and Optimization</i> offers the basic tools to design or synthesize machine elements and assembly of prospective elements in systems or products. It contains the necessary knowledge base, computer aided design, and optimization tools to define appropriate geometry and material selection of machine elements. A comprehensive text for each element includes: a chart, excel sheet, a MATLAB^® program, or an interactive program to calculate the element geometry to guide in the selection of the appropriate material.</p><p>The book contains an introduction to machine design and includes several design factors for consideration. It also offers information on the traditional rigorous design of machine elements. In addition, the author reviews the real design synthesis approach and offers material about stresses and material failure due to applied loading during intended performance. This comprehensive resource also contains an introduction to computer aided design and optimization. This important book:</p><ul><li>Provides the tools to perform a new direct design synthesis rather than design by a process of repeated analysis</li><li>Contains a guide to knowledge-based design using CAD tools, software, and optimum component design for the new direct design synthesis of machine elements</li><li>Allows for the initial suitable design synthesis in a very short time</li><li>Delivers information on the utility of CAD and Optimization</li><li>Accompanied by an online companion site including presentation files</li></ul><p>Written for students of engineering design, mechanical engineering, and automotive design. <i>Machine Design with CAD and Optimization</i> contains the new CAD and Optimization tools and defines the skills needed to generate real design synthesis of machine elements and systems on solid ground for better products and systems.</p>

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